System and method for guiding a tubular along a borehole

ABSTRACT

A system for monitoring and guiding a tubular downhole including a tubular including at least one sensor, a plurality of extended reach systems including at least two of a lubricant delivery system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular, and a controller operatively connected to the at least one sensor. The controller is configured and disposed to monitor parameters on the tubular and selectively activate one or more of the plurality of extended reach systems based on monitored parameters.

BACKGROUND

In the resource exploration and recovery industry, boreholes are formed in a formation for the purpose of locating and recovering various formation fluids. Boreholes extend to great depths and may include laterals that extend up to 10,000 feet (3,048-meters) or longer. Guiding tubulars, such as coiled tubing along such lengths can prove to be difficult. During insertion, friction between the coiled tubing and the formation may slow or stop downward progress at a coiled tubing lock-up depth which may vary depending upon formation conditions.

Various techniques have been developed that help operators overcome friction and allow coiled tubing to be directed to desired depths. For example, lubricants, such as drilling mud, may be employed to help reduce friction between coiled tubing and formation surfaces. Vibratory tools which may provide axial forces of between about 500 lbf (687-Joules) and about 5,000 lbf (6,799-Joules) may also be employed. Tractors, which may exert between 5,000 lbf and about 10,000 lbf (13,558-Joules) may also be used to pull coiled tubing to a desired depth.

Each of the above systems include advantages and disadvantages. For example, while lubricants have been shown to reduce friction by as much as about 40% to about 60%, continuous pumping is required. Further, a large volume of fluid must be stored and effectively managed. Vibratory tools such as a fluid hammer tool, may reduce friction by about 10% to about 20%. However, such tools are often less effective near or below the lock-up depth. Finally, tractors are less effective when the formation includes debris, proppant/sand or other issues that may reduce traction. Accordingly, the art would be appreciative of new methods and systems for guiding tubulars, such as coiled tubing, to desired depths in a formation.

SUMMARY

Disclosed is a system for monitoring and guiding a tubular downhole including a tubular including at least one sensor, a plurality of extended reach systems including at least two of a lubricant delivery system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular, and a controller operatively connected to the at least one sensor. The controller is configured and disposed to monitor parameters on the tubular and selectively activate one or more of the plurality of extended reach systems based on monitored parameters.

Also disclosed is a resource recovery and exploration system including a first system and, a second system including a tubular supporting a sensor. The tubular is fluidically connected to the first system. A plurality of extended reach systems including at least two of a lubricant delivery system arranged at the first system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular. A controller is operatively connected to the at least one force sensor. The controller is configured and disposed to monitor forces on the tubular and selectively activate one or more of the plurality of extended reach systems.

Further disclosed is a method of guiding a tubular into a formation including sensing a first force through a sensor operatively associated with a tubular moving into a borehole formed in a formation, activating a first one of a plurality extended reach systems based on the first force, detecting a second force on the tubular, and activating a second one of the plurality of extended reach systems based on the second force.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 depicts a resource exploration and recovery system having system for guiding a tubular along a borehole, in accordance with an exemplary embodiment;

FIG. 2 depicts a block diagram illustrating a tubular monitoring system, in accordance with an aspect of an exemplary embodiment; and

FIG. 3 depicts a flow chart illustrating a method of guiding a tubular along a borehole, in accordance with an aspect of an exemplary embodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

A resource exploration system, in accordance with an exemplary embodiment, is indicated generally at 10, in FIG. 1. Resource exploration system 10 should be understood to include well drilling operations, resource extraction and recovery, CO₂ sequestration, and the like. Resource exploration system 10 may include a first system 14 operatively connected to a second system 16. First system 14 may take the form of a surface system 20 including controls 24, pumps 30 and a lubricant delivery system 32 that may be operatively connected to controls 24 and pumps 30. Second system 16 may take the form of a downhole system 36 extending into a borehole 38 formed in a formation 40. In an embodiment, borehole 38 may include a main bore 44 and one or more laterals 48.

Second system 16 may include one or more tubulars 58 that extend into borehole 38. Tubulars 58 may take the form of a coiled tubing 62 having a terminal end portion 66. Tubular 58 is may include one or more sensors 70 and a tractor 74 coupled adjacent terminal end portion 66. Sensors 70 may detect various forces on tubular 58 including pressure torque, strain, temperature and the like. Sensors 70 are operatively connected to controls 24 at first system 14. Sensors 70 may be calibrated to downhole conditions including pressure, temperature, fluid type and the like to increase measurement accuracy. Sensors 70 may, for example, detect forces, that may include pressure and temperature, on tubular 58 associated with movement into borehole 38, and particularly, into lateral 48. More specifically, as tubular 58 travels further and further into borehole 38, frictional forces develop that make progress difficult.

In accordance with an exemplary embodiment, resource exploration and recovery system 10 includes a tubular monitoring system 80 operatively connected to sensors 70 as well as a plurality of extended reach systems 90 as shown in FIG. 2. Extended reach systems 90 promote movement of tubular 58 into borehole 38 and may include lubricant delivery system 32, tractor 74 as well as vibratory tools 92 which may include a fluid hammer 94. Tubular monitoring system 80 may include a controller 110, a CPU 112, non-volatile memory 114 and an extended reach control module 116 which may be co-located or part of separate systems. Extended reach control module 116 may selectively control or may provide guidance for orchestrating selectively control of one or more of extended reach systems 90 as will be discussed herein.

Reference will now follow to FIG. 3 in describing a method 200 of guiding a tubular along a borehole, in accordance with an aspect of an exemplary embodiment. In block 204 tubular 58 is guided into borehole 38 along main bore 44 and into lateral 48. In block 206, tubular monitoring system 80 senses forces on tubular 58. If forces are below a selected threshold, tubular 58 is moved further into borehole 38. However, if the sensed forces are above a first force threshold, control module 116 may activate a first one of extended reach systems 90 in block 208. For example, control module 116 may activate lubricate delivery system 32. It should be understood, that lubricant delivery system may also be activated as tubular 58 is introduced into borehole 38. It should also be understood that the term “activate” includes providing guidance to an operator to activate lubricant delivery system 32.

In further accordance with an exemplary aspect, in block 210 a determination is made, through data received from one or more of sensors 70, whether forces on tubular 58 are above a second selected threshold. If the forces have not exceed the second threshold, tubular 58 may continue into borehole 38 with, for example, lubricant. If, however, the forces on tubular 58 have exceeded the second threshold, control module 116 may activate another of the plurality of extended reach systems 90. For example, control module 116 may activate vibratory tools 92 in block 212. Vibratory tools 92 may be active with or without lubricant delivery system 32 also being active. That is, depending upon forces on tubular 58, a determination may be made that activation of vibratory tools 92 may be desired or, vibratory tools 92 together with lubricant may be helpful in guiding tubular 58 further into borehole 38. It should also be understood that the term “activate” includes providing guidance to an operator to activate vibratory tools 92.

In still further accordance with an exemplary aspect, in block 214 a determination is made, through data received from one or more of sensors 70, whether forces on tubular 58 are above a third selected threshold. If the forces have not exceeded the third threshold, tubular 58 may continue into borehole 38 with, for example, vibratory tools 92 being active. Of course, lubricant delivery system 32 may also be active. If, however, the forces on tubular 58 have exceeded the third threshold, control module 116 may activate another of the plurality of extended reach systems 90. For example, control module 116 may activate tractor 74 in block 218 to pull tubular 58 along, for example, lateral 48. It should also be understood that the term “activate” includes providing guidance to an operator to activate tractor 74. Tractor 74 may be a sole motive force acting upon tubular 58 or tractor 74 may be operated in connection with one or more additional ones of the plurality of extended reach systems 90.

At this point it should be understood that the exemplary embodiments describe a system for motivating a tubular to a desired position within a borehole. The system senses forces at a downhole end of the tubular. or on a bottom hole assembly (BHA) located at the downhole end of the tubular, and determines which extended reach systems may be most helpful when activated singly and/or in combination to achieve the desired position. The system may employ thresholds based on prior operations and/or pre-job calculation to determine in which order, and/or in which combination extended reach tools may be activated to reduce stresses on the tubular and achieve the selected position.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1

A system for monitoring and guiding a tubular downhole including a tubular including at least one sensor, a plurality of extended reach systems including at least two of a lubricant delivery system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular and a controller operatively connected to the at least one sensor, the controller being configured and disposed to monitor parameters on the tubular and selectively activate one or more of the plurality of extended reach systems based on monitored parameters.

Embodiment 2

The system according to any prior embodiment, wherein the plurality of extended reach systems includes each of the lubricant delivery system, the vibratory tool operatively connected to the tubular, and the tractor mechanically connected to the tubular.

Embodiment 3

The system of any prior embodiment, wherein the tubular comprises coiled tubing having a terminal end portion.

Embodiment 4

The system of any prior embodiment, wherein the plurality of extended reach systems includes the tractor operatively connected adjacent the terminal end portion of the coiled tubing.

Embodiment 5

The system of any prior embodiment, wherein the controller is configured to sequentially selectively control the plurality of extended reach systems.

Embodiment 6

The system according to any prior embodiment, wherein the controller monitors the at least one force sensor and selectively controls the plurality of extended reach systems in real time.

Embodiment 7

A resource recovery and exploration system including a first system, a second system including a tubular supporting a sensor, the tubular being fluidically connected to the first system, a plurality of extended reach systems including at least two of a lubricant delivery system arranged at the first system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular and a controller operatively connected to the at least one force sensor, the controller being configured and disposed to monitor forces on the tubular and selectively activate one or more of the plurality of extended reach systems.

Embodiment 8

The resource recovery and exploration system according to any prior embodiment, wherein the plurality of extended reach systems includes each of the lubricant delivery system, the vibratory tool operatively connected to the tubular, and the tractor mechanically connected to the tubular.

Embodiment 9

The resource recovery and exploration system of any prior embodiment, wherein the tubular comprises coiled tubing having a terminal end portion.

Embodiment 10

The resource recovery and exploration system of any prior embodiment, wherein the plurality of extended reach systems includes the tractor operatively connected adjacent the terminal end portion of the coiled tubing.

Embodiment 11

The resource recovery and exploration system of any prior embodiment, wherein the controller is configured to sequentially selectively control the plurality of extended reach systems.

Embodiment 12

The resource recovery and exploration system according to any prior embodiment, wherein the controller monitors the at least one force sensor and selectively controls the plurality of extended reach systems in real time.

Embodiment 13

A method of guiding a tubular into a formation including sensing a first force through a sensor operatively associated with a tubular moving into a borehole formed in a formation, activating a first one of a plurality extended reach systems based on the first force, detecting a second force on the tubular and activating a second one of the plurality of extended reach systems based on the second force.

Embodiment 14

The method any prior embodiment, further including sensing a third force on the tubular and activating a third one of the plurality of extended reach systems based on the third force.

Embodiment 15

The method of any prior embodiment, wherein activating the first, second, and third one of the plurality of extended reach systems includes responding in real time to forces experienced by the tubular moving into the borehole.

Embodiment 16

The method of any prior embodiment, further including calibrating the sensor to downhole conditions.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. 

What is claimed is:
 1. A system for monitoring and guiding a tubular downhole comprising: a tubular including at least one sensor, a plurality of extended reach systems including at least two of a lubricant delivery system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular; and a controller operatively connected to the at least one sensor, the controller being configured and disposed to monitor parameters on the tubular and selectively activate one or more of the plurality of extended reach systems based on monitored parameters.
 2. The system according to claim 1, wherein the plurality of extended reach systems includes each of the lubricant delivery system, the vibratory tool operatively connected to the tubular, and the tractor mechanically connected to the tubular.
 3. The system of claim 1, wherein the tubular comprises coiled tubing having a terminal end portion.
 4. The system of claim 3, wherein the plurality of extended reach systems includes the tractor operatively connected adjacent the terminal end portion of the coiled tubing.
 5. The system of claim 1, wherein the controller is configured to sequentially selectively control the plurality of extended reach systems.
 6. The system according to claim 1, wherein the controller monitors the at least one force sensor and selectively controls the plurality of extended reach systems in real time.
 7. A resource recovery and exploration system comprising: a first system; a second system including a tubular supporting a sensor, the tubular being fluidically connected to the first system; a plurality of extended reach systems including at least two of a lubricant delivery system arranged at the first system, a vibratory tool operatively connected to the tubular, and a tractor mechanically connected to the tubular; and a controller operatively connected to the at least one force sensor, the controller being configured and disposed to monitor forces on the tubular and selectively activate one or more of the plurality of extended reach systems.
 8. The resource recovery and exploration system according to claim 7, wherein the plurality of extended reach systems includes each of the lubricant delivery system, the vibratory tool operatively connected to the tubular, and the tractor mechanically connected to the tubular.
 9. The resource recovery and exploration system of claim 7, wherein the tubular comprises coiled tubing having a terminal end portion.
 10. The resource recovery and exploration system of claim 9, wherein the plurality of extended reach systems includes the tractor operatively connected adjacent the terminal end portion of the coiled tubing.
 11. The resource recovery and exploration system of claim 7, wherein the controller is configured to sequentially selectively control the plurality of extended reach systems.
 12. The resource recovery and exploration system according to claim 7, wherein the controller monitors the at least one force sensor and selectively controls the plurality of extended reach systems in real time.
 13. A method of guiding a tubular into a formation comprising: sensing a first force through a sensor operatively associated with a tubular moving into a borehole formed in a formation; activating a first one of a plurality extended reach systems based on the first force; detecting a second force on the tubular; and activating a second one of the plurality of extended reach systems based on the second force.
 14. The method of claim 13, further comprising: sensing a third force on the tubular; and activating a third one of the plurality of extended reach systems based on the third force.
 15. The method of claim 14, wherein activating the first, second, and third one of the plurality of extended reach systems includes responding in real time to forces experienced by the tubular moving into the borehole.
 16. The method of claim 13, further comprising: calibrating the sensor to downhole conditions. 